Method and apparatus for dry cast facing concrete deposition

ABSTRACT

An apparatus and method for manufacturing masonry blocks using a face mix shuttle comprising an angled shovel for depositing a controllable amount of face mix onto a surface of a masonry block.

RELATED APPLICATIONS

The present application claims benefit of U.S. Provisional PatentApplication No. 61/838,205, entitled “Masonry Blocks,” filed Jun. 21,2013, which is hereby incorporated by reference for all purposes.

TECHNICAL FIELD

The present disclosure relates to production of concrete blocks, andmore specifically to a method and apparatus for controlling the dry castfacing of concrete blocks using a face mix shovel box.

BACKGROUND OF THE INVENTION

Concrete blocks are often molded using a mixture of different materialswith various colors for aesthetic pleasure. However, it is difficult tocontrol the distribution of the expensive, colorful materials used tocreate the multicolored concrete blocks leading to unpredictable resultsand wasted resources.

SUMMARY OF THE INVENTION

An apparatus and method for manufacturing masonry blocks using a facemix shuttle comprising an angled shovel for depositing a controllableamount of face mix onto a surface of a masonry block.

Other systems, methods, features, and advantages of the presentdisclosure will be or become apparent to one with skill in the art uponexamination of the following drawings and detailed description. It isintended that all such additional systems, methods, features, andadvantages be included within this description, be within the scope ofthe present disclosure, and be protected by the accompanying claims.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Aspects of the disclosure can be better understood with reference to thefollowing drawings. The components in the drawings are not necessarilyto scale, emphasis instead being placed upon clearly illustrating theprinciples of the present disclosure. Moreover, in the drawings, likereference numerals designate corresponding parts throughout the severalviews, and in which:

FIGS. 1a-m are diagrams of a shovel box face mix paver machine andmethod of using such in accordance with an exemplary embodiment of thepresent disclosure;

FIG. 2 is a diagram of face mix shuttle in accordance with an exemplaryembodiment of the present disclosure; and

FIG. 3 is a diagram of an algorithm for controlling a manufacturingprocess, in accordance with an exemplary embodiment of the presentdisclosure.

DETAILED DESCRIPTION OF THE INVENTION

In the description that follows, like parts are marked throughout thespecification and drawings with the same reference numerals. The drawingfigures might not be to scale and certain components can be shown ingeneralized or schematic form and identified by commercial designationsin the interest of clarity and conciseness.

FIG. 1a is a diagram 100 of a shovel box face mix paver machine inaccordance with an exemplary embodiment of the present disclosure. Asshown in FIGS. 1a and 1b , the machine comprises a base mix chute 105providing a base mix supply 115 to a base mix shuttle 110, a mold 120configured to be placed into a loading zone on a steel plate 125, a facemix chute 130 providing face mix materials 150, 155, 160, to a face mixshuttle 135, and a press 165. Each of the components of the mold machinecan be formed from steel or other suitable materials, and are typicallydisposed on an infrastructure assembly (not shown) that maintains thecomponents in a predetermined position (such as for base mix chute 105and face mix chute 130), or which provides a motive force for moving thecomponent (such as for face mix shuttle 135 and press 165), as discussedfurther herein. In addition, supply conveyors (not shown) are providedto base mix chute 105 and face mix chute 130 to provide base mixmaterials and face mix materials.

In one embodiment of the present disclosure, face mix shuttle 135comprises a retainer plate 140 and a shovel 145 which collectivelyoperate to control the flow of face mix materials 150, 155, 160 into themold.

FIGS. 1b-1m are diagrams showing various stages of operation of the moldmachine 100. As shown in FIG. 1b , in the first stage of operation, basemix chute 105 provides base mix supply 115 to base mix shuttle 110. Inone embodiment of the present disclosure, base mix supply 115 can beconcrete, a mixture of concrete and other materials, or any otherconventional semi-dry masonry material capable of serving as a base ofthe concrete or masonry blocks. It is understood that base mix supply115 can be rough and functional with minimal aesthetic value. Base mixchute 105 can operate with any suitable conventional hopper or base mixstorage unit to deliver base mix supply 115. In certain embodiments ofthe present disclosure, the amount of base mix supply 115 delivered tothe base mix shuttle 110 can be enough that reloading is not necessaryduring each successive cycle of operating base mix shuttle 110.

Also during the stage of operation shown in FIG. 1b , face mix chute 130provides face mix materials 150, 155, 160 to face mix shuttle 135comprising of retainer plate 140 and shovel 145. Face mix materials 150,155, 160 can be concrete, a mixture of concrete and other materials, orany other suitable conventional semi-dry material suitable for providingsome aesthetic functionality to a surface of the concrete block. Facemix materials 150, 155, 160 are generally more expensive than base mixsupply 115 and are of different colors or textures. In one embodiment ofthe present disclosure, face mix materials 150, 155, 160 can beseparately deposited into face mix shuttle 135 by face mix chute 130 toprevent the mixing of the expensive, multi-colored face mix materials.By keeping face mix materials 150, 155, 160 separate, it is possible tomore precisely control the eventual placement and distribution of thecolorful, aesthetically-pleasing face mix materials onto a surface ofthe concrete block.

As shown in FIG. 1d , once base mix shuttle 110 has received base mixsupply 115 from base mix chute 105, base mix shuttle 110 moves in afirst reference direction over mold 120 placed on steel plate 125, asindicated by the arrow. As shown in FIG. 1e , once base mix shuttle 110completes movement in the first reference direction, base mix shuttle110 returns to the original position, as indicated by the arrow. Whilebase mix shuttle 110 is traveling over the mold in the first referencedirection and return trip, base mix shuttle 110 is depositing base mixsupply 115 into mold 120.

Referring now to FIGS. 1f-1g , once base mix supply 115 is depositedinto mold 120, press 165 is lowered into mold 120 to deliver anintermediate tamp to base mix supply 115. During this intermediate tamp,a vibrating force can be applied to mold 120 containing base mix supply115 to ensure that base mix supply 115 is evenly distributed from asuitable vibrating device (not shown). In one embodiment of the presentdisclosure, the vibrating force can be applied for about one-halfsecond. Also during the intermediate tamp, press 165 applies acompression force onto base mix supply 115 so that base mix supply 115no longer completely fills mold 120. As shown in FIG. 1g , once theintermediate tamp is complete, press 165 returns to the originalposition.

Referring now to FIGS. 1h-1j , once the intermediate tamp is complete,face mix shuttle 135 moves rapidly in a second reference direction overmold 120, as shown by the arrow. During this rapid movement in thesecond reference direction, face mix materials 150, 155, 160 are notdeposited into mold 120, due to the force of the acceleration of facemix shuttle 135 in the second reference direction. However, once facemix shuttle 135 has completed the rapid movement in the second referencedirection, face mix shuttle 135 returns to its original position at aslower speed, which permits face mix materials 150, 155, 160 to passthrough a space between retainer plate 140 and shovel 145. The depositedface mix materials 170 form an aesthetically-pleasing surface on top ofbase mix supply 115.

Referring now to FIG. 1k , press 165 is lowered into contact with thetop surface of the newly formed concrete block comprising of the basemix supply 115 and face mix materials 170. Press 165 applies acompression force onto the concrete block. After this compression forceis applied, a vibrational device associated with press 165 applies avibration force to mold 120 and the concrete block contained within mold120.

Referring now to FIG. 1l , once press 165 has been applied and avibration force has been applied to mold 120 and the concrete block,mold 120 is lifted a sufficient distance to expose the concrete block onsteel plate 125 in the direction shown by the arrow. As shown in FIG. 1m, press 165 is then lifted off of the top surface of the concrete block.The concrete block is then transported on steel plate 125 to a curinglocation to allow for heating and curing of the final product. Mold 120is then lowered to its original position on steel plate 125 and theentire process can be repeated.

FIG. 2 is a diagram of face mix shuttle 135 including retainer plate 140and shovel 145. Shovel 145 is disposed at an angle of between about 60degrees and about 135 degrees, where the angle can be adjusted tocontrol the amount of mixing and interaction between face mix materials150, 155, 160, and also to prevent face mix materials 150, 155, 160 fromsliding off shovel 145 and outside of face mix shuttle 135 as it ismoved. By using shovel 145 instead of a flat wall (as is the case withthe base mix shuttle), shovel 145 lifts face mix materials 150, 155, 160as face mix shuttle 135 moves, such that the arrangement of face mixmaterials 150, 155, 160 is maintained, and face mix materials 150, 155,160 do not blend into each other as quickly. In this manner, a clearerdemarcation between semi-randomly distributed areas of face mixmaterials 150, 155, 160 over the top of base mix supply 115 can berealized prior to the application of press 165 onto mold 120. In oneembodiment of the present disclosure, the distance X between retainerplate 140 and shovel 145 can be between about 2 inches and about 12inches. This distance can be increased from inches and decreased from 12inches in order to control the deposition of face mix materials 150,155, 160 onto base mix that is contained within mold 120.

Shovel 145 is moved by piston 170, which can be a hydraulic piston orother suitable motive forces that can drive shovel 145 at different andcontrollable speeds. Controller 180 is a programmable controller orother suitable controllers that can receive programming instructions toprovide signals to piston 170 and other components, such as to extendpiston 170 at a first speed that is fast enough to cause face mixmaterials 150, 155, 160 to be lifted as discussed, and to retract piston170 at a second speed that is slow enough to cause face mix materials150, 155, 160 to be distributed onto the surface of the base mix thathas been deposited within mold 120. Controller 180 can also performother suitable sequencing operations, as described further herein.

FIG. 3 is a diagram of an algorithm 300 for controlling a manufacturingprocess, in accordance with an exemplary embodiment of the presentdisclosure. Algorithm 300 can be implemented in hardware or a suitablecombination of hardware and software, and can be software operating in acontroller of a combined press and shuttle box device as discussedherein.

Algorithm 300 begins at 302, where a fill command is generated to fill abase mix shuttle using the base mix chute. In one exemplary embodiment,the fill command can cause an actuator to open a door from a gravity-fedbase mix supply for a predetermined period of time and then to close, soas to allow a predetermined amount of base mix to be provided to thebase mix shuttle, or other suitable processes can also or alternativelybe used. The algorithm then proceeds to 304.

At 304, a fill command is generated to fill the face mix shuttle usingthe face mix chute. In one exemplary embodiment, the fill command cancause a plurality of actuators to each open a door in a predeterminedsequence from a gravity-fed face mix supply for a predetermined periodof time and then to close, so as to allow a predetermined amount of facemix to be provided to the face mix shuttle, or other suitable processescan also or alternatively be used. The algorithm then proceeds to 306.

At 306, a movement command is generated to move the base mix shuttle ina first reference direction over the mold to deposit a base mix supplyinto the mold. Once the base mix shuttle completes this movement, thebase mix shuttle returns to the original position. In one exemplaryembodiment, the base mix shuttle can be coupled to a hydraulic piston orother suitable motive devices, and can be moved at a first speed to aposition over the mold and then returned to the starting position at asecond speed, where the first speed and the second speed can be the sameor different. The algorithm then proceeds to 308.

At 308, a press command is generated to cause a hydraulic press or othersuitable press devices to be lowered to engage with the base mixmaterials deposited into the mold. Once the press has exerted a pressureonto the top surface of the materials in the mold, a vibration commandis generated to exert a vibration on the contents of the mold forbetween one-half and two seconds. A release command is then generated tocause the press to return to a position above the mold and out of theway of the face mix shuttle, and the algorithm then proceeds to 310.

At 310, a movement command is generated to move the face mix shuttle ina second reference direction over the mold to deposit a face mix supplyinto the mold. In one exemplary embodiment, the face mix shuttle can becoupled to a hydraulic piston or other suitable motive devices, whichcan be actuated to move at a first speed and with an associatedacceleration. Based on the acceleration force of the face mix shuttle asit moves in the first direction, the face mix is pushed over the shoveland prevented from falling through the opening, such that no face mixsupply is deposited into the mold during the initial trip in the secondreference direction. However, once the trip in the second referencedirection is completed, the face mix in the face mix shuttle returns toits original position over the opening, and the face mix shuttle ismoved in a second direction at a slower speed, so as to allow the facemix to fall through the opening in the face mix shuttle. During thisreturn trip, the face mix shuttle deposits a face mix supply onto thetop layer of the base mix supply in the mold. By depositing the face mixsupply only during the return trip, the process avoids mixture of theface mix supply deposited during the original movement over the mold andsubsequent return trip to the original position. In one exemplaryembodiment of the present disclosure, during the return trip of the facemix shuttle the retainer plate contacts and levels a top surface of theface mix supply deposited into the mold. The algorithm then proceeds to312.

At 312, a press command is generated to cause the press to lower ontoand engage with the face mix and base mix materials deposited into themold, such as by actuating a hydraulic supply to the press or in othersuitable manners. Once the press has exerted a pressure onto the topsurface of the materials in the mold, a vibration command is generatedto exert a vibration on the contents of the mold for between one-halfand two seconds. The algorithm then proceeds to 314.

At 314, a movement command is generated to strip the mold from theconcrete block contained within the mold. In one exemplary embodiment,the mold can be coupled to a piston or other suitable motive device, andcan be raised or lowered to allow the base mix and face mix (which canbe disposed on a moveable steel plate or other suitable structures) tobe exposed. During the stripping of the mold, the press can remainengaged with the top surface of the base mix and the face mix, which nowform an uncured concrete block. Once the mold has been lifted and nolonger contacts the concrete block, a command can be generated to causethe hydraulic press to return to an open position. The algorithm thenproceeds to 316.

At 316, a reset command is generated wherein the concrete block istransported to a curing location, such as by using a belt drive or othersuitable motive devices, and the mold is returned to the originalposition.

It should be emphasized that the above-described embodiments are merelyexamples of possible implementations. Many variations and modificationsmay be made to the above-described embodiments without departing fromthe principles of the present disclosure. All such modifications andvariations are intended to be included herein within the scope of thisdisclosure and protected by the following claims.

What is claimed is:
 1. A face mix paver machine comprising: a mold; aface mix shuttle further comprising a shovel configured to lift at leastone face mix masonry compound as the face mix shuttle travels in adirection generally towards the mold; and wherein the face mix shuttlefurther comprises a retainer plate disposed about a front edge of theshovel, wherein the at least one face mix masonry compound is depositedinto the mold through an opening between the retainer plate and thefront edge of the shovel.
 2. The face mix paver machine of claim 1,wherein the distance between the front edge of the shovel and theretainer plate is between about 2 inches and 8 inches.
 3. The face mixpaver machine of claim 1, wherein the distance between the front edge ofthe shovel and the retainer plate is greater than 2 inches.
 4. The facemix paver machine of claim 1, wherein the distance between the frontedge of the shovel and the retainer plate is less than 8 inches.
 5. Theface mix paver machine of claim 1, wherein the shovel has an internalsurface angle of between about 60 degrees and about 135 degrees.
 6. Theface mix paver machine of claim 1, wherein the shovel has an internalsurface angle of greater than 60 degrees.
 7. The face mix paver machineof claim 1, wherein the shovel has an internal surface angle of lessthan 135 degrees.
 8. The face mix paver machine of claim 1 furthercomprising a piston coupled to the face mix shuttle and configured tomove the face mix shuttle at a speed sufficient to lift the plurality offace mix masonry compounds over the shovel as the face mix shuttletravels over the mold in the direction generally toward the mold.
 9. Theface mix paver of claim 8 further comprising a controller coupled to thepiston, the controller configured to generate a first control signal tocause the piston to travel at a first speed in the direction generallytoward the mold, and to travel at a second speed in a second direction.10. The face mix paver machine of claim 1, wherein the distance betweenthe front edge of the shovel and the retainer plate is greater than 2inches, and the face mix masonry compound comprises a plurality ofdifferent face mix masonry compounds that are deposited into a spacebetween the front edge of the shovel and the retainer plate.
 11. A facemix paver machine comprising: a mold; and a face mix shuttle configuredto move over the mold after it has been filled with a first concretemixture, the face mix shuttle further comprising a shovel configured tolift at least one face mix masonry compound as the face mix shuttletravels in a first direction generally towards the mold and to allow theface mix masonry compound to be deposited over the concrete mixture asthe face mix shuttle is moved in a second direction generally away fromthe mold; and wherein the face mix shuttle further comprises a retainerplate disposed about a front edge of the shovel, wherein the at leastone face mix masonry compound is deposited into the first concretemixture in the mold through an opening between the retainer plate andthe front edge of the shovel as the face mix shuttle moves in the seconddirection.
 12. The face mix paver machine of claim 11, wherein thedistance between the front edge of the shovel and the retainer plate isbetween about 2 inches and 8 inches, and the face mix masonry compoundis deposited into a space between the front edge of the shovel and theretainer plate.
 13. The face mix paver machine of claim 11, wherein thedistance between the front edge of the shovel and the retainer plate isless than 8 inches, and the retainer plate pushes the face mix masonrycompound over the first concrete mixture as the face mix shuttle movesin the second direction.
 14. The face mix paver machine of claim 11,wherein the shovel has an internal surface angle of between about 60degrees and about 135 degrees and forces the face mix masonry compoundagainst the retainer plate as the face mix shuttle stops movement in thefirst direction and before the face mix shuttle starts movement in thesecond direction.
 15. The face mix paver machine of claim 11, whereinthe shovel has an internal surface angle of greater than 60 degrees andpushes the face mix masonry compound in a direction towards the retainerplate as the face mix shuttle stops movement in the first direction andbefore the face mix shuttle starts movement in the second direction. 16.The face mix paver machine of claim 11, wherein the shovel has aninternal surface angle of less than 135 degrees and forces the face mixmasonry compound in a direction towards the retainer plate as the facemix shuttle stops movement in the first direction and before the facemix shuttle starts movement in the second direction.
 17. The face mixpaver machine of claim 11 further comprising a piston coupled to theface mix shuttle and configured to move the face mix shuttle at a speedsufficient to lift the plurality of face mix masonry compounds over theshovel as the face mix shuttle travels over the mold in the directiongenerally toward the mold.
 18. The face mix paver of claim 17 furthercomprising a controller coupled to the piston, the controller configuredto generate a first control signal to cause the piston to travel at afirst speed in the direction generally toward the mold, and to travel ata second speed in a second direction.